The main aim of this work is to obtain heterogeneous, zirconocene aluminohydride/methylaluminoxane (MAO) polymerization catalysts, without using inorganic carriers like silica. The syntheses of zirconocenium ion‐based clathrates, formed from aluminohydride zirconocene complexes activated with MAO, are reported here. Several different approaches were examined for the synthesis of these clathrate compositions; in one approach the catalyst (nBuCp2ZrH3AlH2/MAO) was first prepared in toluene solution, and the clathrate phase then generated by addition of silicone oil. An alternate approach involved reaction of silicone oil or another clathrate‐forming additive (e.g. KCl) with MAO to form a solidified clathrate, and then introducing the zirconocene aluminohydride complex (nBuCp2ZrH3AlH2). The clathrate catalysts were probed in the polymerization of ethylene in hydrocarbon slurry, without using additional co‐catalyst (MAO), or at very low concentrations of modified MAO (MMAO 7, 13 wt‐% in iso‐octane). The catalytic activities of the solid clathrate catalysts were compared as well as the morphology and properties of the polyethylene synthesized in slurry.
The kinetic performance of metallocene type catalysts as well as their instantaneous activity is determined on line by two independent methods in the semi-batch polymerization of ethylene via metallocenes. The first-principle basis of both methods is described and guidelines for their implementation at a laboratory scale reactor are offered. Polymerization tests were conducted with two heterogenized metallocene catalysts showing that the direct method (based on ethylene flow measurement) and the calorimetric method (based on energy balances and developed here) report equivalent high quality information. This last method can be readily used by the chemical practitioner as the notions and tools required for its implantation are easily grasped; it also has the advantage of requiring a low cost instrumentation (only thermocouples), whereas the direct method needs a relatively more sophisticated equipment (mass flow meter).
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